Systems and methods for spill detection

ABSTRACT

A pharmaceutical filling system for a high volume pharmacy is described. The system can include a spill detection subsystem and method. The system can include a cameras to take images that a processed to determine presence of a spilled pharmaceutical. A mirror portion is provided so that the camera can take images of the entire field of the filling area. The mirror portion can be a concave mirror that increases the field of view of the camera. A light panel can illuminate the field of view to allow the camera to take high speed images. A controller can receive a series of at least two images captured by the camera and determine whether an object in the captured images is a spilled pharmaceutical.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 14/725,418 filed on May 29, 2015, the entiredisclosure of which is incorporated herein by reference.

FIELD

The field relates to automated filling centers, and more particularly toa high volume fulfillment center, e.g., a high volume pharmacy and tosystems and methods used in filling prescriptions and prescriptionorders at a high volume pharmacy.

BACKGROUND

A high-volume pharmacy may process and fill a large number ofprescriptions and prescription orders. Automated systems may be used bya high volume pharmacy to process and fulfill prescriptions.

Frequently, more than one prescription drug is required to complete aprescription order. Portions of the prescription order may be fulfilledin different areas of the high-volume pharmacy. After fulfillment, thefulfilled prescriptions may be gathered into a complete prescriptionorder for shipping.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of an example system, according to an exampleembodiment;

FIG. 2 is a block diagram of an example order processing device that maybe deployed within the system of FIG. 1, according to an exampleembodiment;

FIG. 3 is a perspective view of a pallet, according to an exampleembodiment;

FIG. 4 is perspective view of an automatic dispensing device and a spilldetection system, according to an example embodiment;

FIG. 5 is a side elevation view of a prefill assembly and a palletassembly of an automatic dispensing device, and a spill detectionsystem, according to an example embodiment.

FIG. 6 is a top plan view of a pallet assembly of an automaticdispensing device and a spill detection system, according to an exampleembodiment;

FIG. 7 is a top plan block diagram of a spill detection system,according to an example embodiment;

FIG. 8 is a front elevation view of a camera portion of a spilldetection system, according to an example embodiment;

FIG. 9 is block diagram of a control unit of a spill detection system,according to an example embodiment;

FIG. 10 is block diagram of a filling status subsystem of the controlunit of FIG. 9, according to an example embodiment;

FIG. 11 is block diagram of an image analysis subsystem of the controlunit of FIG. 9, according to an example embodiment;

FIG. 12 is a flow diagram of a method for detecting spills, according toan example embodiment.

FIG. 13 is a side elevation view of a pallet mount, according to anexample embodiment.

FIG. 14 is a block diagram of a machine in the example form of acomputer system within which a set of instructions for causing themachine to perform any one or more of the methodologies discussed hereinmay be executed or stored.

DETAILED DESCRIPTION

Example systems and methods for spill detection are described. In thefollowing description, for purposes of explanation, numerous specificdetails are set forth in order to provide a thorough understanding ofexample embodiments. It will be evident, however, to one of ordinaryskill in the art that these embodiments may be practiced without thesespecific details.

Generally, a prescription order is generated for a high volume pharmacy.The prescription order may include more than one prescription drug forfulfillment. Each prescription drug in a prescription order is an ordercomponent of the prescription order. Generally, the order components arepill bottles or other packaging having a quantity of a prescription drugtherein.

The prescription drugs may be dispensed at various sections of the highvolume pharmacy. Some prescription orders may require manual fulfillmentof order components. Distribution of order components necessitatingmanual fulfillment is provided by a distribution section and one or moremanual sections. In general, manual handling includes manual fulfillmentof prescription drugs. Manual handling occurs at one or more than onemanual sections, from which the order component exits the manualfulfillment device.

FIG. 1 is a block diagram of an example system 100, according to anexample embodiment. While the system 100 is generally described as beingdeployed in a high volume fulfillment center (e.g., a mail orderpharmacy, a direct delivery pharmacy, and the like), the system 100and/or components thereof may otherwise be deployed. The system 100 mayinclude an order processing device 102 in communication with a benefitmanager device 106 over a network 104. Additional devices which may bein communication with the benefit manager device 106 and/or the orderprocessing device 102 over network 104 include: database(s) 108 whichmay store one or more than one of order data 110, member data 112,claims data 114, drug data 116, prescription data 118, and plan sponsordata 120; pallet sizing and pucking device(s) 122; loading device(s)124; inspect device(s) 126; unit of use device(s) 128; automateddispensing device(s) 130; manual fulfillment device(s) 132; reviewdevice(s) 134; imaging device(s) 136; cap device(s) 138; accumulationdevice(s) 140; packing device(s) 142; and unit of use packing device(s)144. The system 100 may also include additional devices.

The order processing device 102 may receive information aboutprescriptions being filled at a pharmacy in which the order processingdevice 102 is deployed. In general, the order processing device 102 is adevice located within or otherwise associated with a pharmacy locationto enable fulfillment of a prescription by dispensing prescriptiondrugs. In some embodiments, the order processing device 102 may be adevice separate from a pharmacy that enables communication with otherdevices located within a pharmacy. For example, the order processingdevice 102 may be in communication with another order processing device102 and/or other devices 122-144 located with a pharmacy. In someembodiments, an external pharmacy order processing device 102 may havelimited functionality (e.g., as operated by a patient requestingfulfillment of a prescription drug) when an internal pharmacy orderprocessing device 102 may have greater functionality (e.g., as operatedby a pharmacy).

The order processing device 102 may track a prescription order as it isfulfilled. A prescription order may include one or more than oneprescription to be filled by the pharmacy. The order processing device102 may make pharmacy routing decisions and/or order consolidationdecisions for a prescription order. The pharmacy routing decisionsinclude what device or devices in the pharmacy are responsible forfilling at least a portion of the prescription order, where the orderconsolidation decisions include whether portions of a prescription orderor multiple prescription orders should be shipped together for a patientor a patient family. The order processing device 102 may operate incombination with the benefit manager device 106.

Examples of the order processing device 102 include a set-top box (STB),a receiver card, a mobile telephone, a personal digital assistant (PDA),a display device, a portable gaming unit, a tablet, and a computingsystem; however other devices may also be used. For example, the orderprocessing device 102 may include a mobile electronic device, such anIPHONE or IPAD device by Apple, Inc., mobile electronic devices poweredby ANDROID by Google, Inc., and a BLACKBERRY device by BlackberryLimited. The order processing device 102 may also include othercomputing devices, such as desktop computing devices, notebook computingdevices, netbook computing devices, gaming devices, and the like. Thedevice 102 may include a processor, a memory to store data andinstructions, and communication functionality. Other types of electronicdevices that can use rules and instructions to execute various functionsmay also be used.

Examples of the network 104 include Mobile Communications (GSM) network,a code division multiple access (CDMA) network, 3rd GenerationPartnership Project (3GPP), an Internet Protocol (IP) network, aWireless Application Protocol (WAP) network, a WiFi network, or an IEEE802.11 standards network, as well as various combinations thereof. Thenetwork 104 may include optical communications. The network 104 may be alocal area network or a global communication network, such as theInternet. Other conventional and/or later developed wired and wirelessnetworks may also be used. In some embodiments, the network 104 mayinclude a prescribing network such as the electronic prescribing networkoperated by Surescripts of Arlington, Va.

The benefit manager device 106 is a device operated by an entity atleast partially responsible for creation and/or management of thepharmacy or drug benefit. While the benefit manager operating thebenefit manager device 106 is typically a pharmacy benefit manager(PBM), other entities may operate the benefit manager device 106 eitheron behalf of themselves, the PBM, or another entity. For example, thebenefit manager may be operated by a health plan, a retail pharmacychain, a drug wholesaler, a data analytics or other type ofsoftware-related company, or the like. In some embodiments, a PBM thatprovides the pharmacy benefit may also provide one or more than oneadditional benefits including a health benefit, a dental benefit, avision benefit, a wellness benefit, a radiology benefit, a pet carebenefit, an insurance benefit, a long term care benefit, a nursing homebenefit, and the like. The PBM may, in addition to its PBM operations,operate one or more than one pharmacy.

Some of the operations of the PBM that operates the benefit managerdevice 106 may include the following. A member (or a person on behalf ofthe member) of a pharmacy benefit plan administered by or through thePBM attempts to obtain a prescription drug at a retail pharmacy locationwhere the member can obtain drugs in a physical store from a pharmacistor pharmacist technician, or in some instances through mail order drugdelivery from a mail order pharmacy location. The member may also obtaina prescription drug directly or indirectly through the use of a machine,such as a kiosk, vending unit, mobile electronic device, or a differenttype of mechanical, electrical, an electronic communication deviceand/or computing device.

The member may have a co-pay for the prescription drug that reflects anamount of money that the member is responsible to pay the pharmacy forthe prescription drug. The money paid by the member to the pharmacy maycome from the personal funds of the member, a health savings account(HSA) of the member or the member's family, a health reimbursementarrangement (HRA) of the member or the member's family, a flexiblespending accounts (FSA) of the member or the member's family, or thelike. An employer of the member may directly or indirectly fund orreimburse the member or an account of the member for the co-pay.

The amount of the co-pay paid by the member may vary by the benefit planof a plan sponsor or client with the PBM. The member's co-pay may bebased on a flat co-pay (e.g., $10), co-insurance (e.g., 10%), and/or adeductible (e.g., for first $500 of annual prescription drug spend) forcertain prescription drugs, certain types of prescription drugs, and/orall prescription drugs.

In certain instances, the member may not pay the co-pay or may only payfor a portion of a co-pay for a prescription drug. For example, if theusual and customary cost for a generic version of a prescription drug is$4, and the member's flat co-pay is $20 for the prescription drug, themember may only pay $4 to receive the prescription drug. In anotherexample involving a worker's compensation claim, no co-pay may be due bythe member for the prescription drug. The co-pay may also vary based onthe channel used to receive the prescription drug. For example, theco-pay for receiving prescription drug from a mail order pharmacylocation may be less than the co-pay for receiving prescription drugfrom a retail pharmacy location.

In conjunction with receiving the co-pay (if any) from the member anddispensing the prescription drug to the member, the pharmacy submits aclaim to the PBM for the prescription drug. The PBM may perform certainadjudication operations including verifying the eligibility of themember, reviewing the formulary of the member to determine appropriateco-pay, coinsurance, and deductible for the prescription drug, andperforming a drug utilization review (DUR) on the member. The PBM thenprovides a response to the pharmacy following performance of at leastsome of the aforementioned operations. As part of the adjudication, theplan sponsor (or the PBM on behalf of the plan sponsor) ultimatelyreimburses the pharmacy for filling the prescription drug when theprescription drug was successfully adjudicated. The aforementionedadjudication operations generally occur before the co-pay is receivedand the prescription drug dispensed. However, the operations may occursimultaneously, substantially simultaneously, or in a different order.In addition, more or less adjudication operations may be performed as atleast part of the adjudication process.

The amount of reimbursement paid to the pharmacy by a plan sponsorand/or money paid by the member may be based at least in part on thetype of pharmacy network in which the pharmacy is included. Otherfactors may be used to determine the amount in addition to the type ofpharmacy network. For example, if the member pays the pharmacy for theprescription without using the prescription drug benefit provided by thebenefit manager, the amount of money paid by the member may be higherand the amount of money received by the pharmacy for dispensing theprescription drug and for the prescription drug itself may be higher.Some or all of the foregoing operations may be performed by executinginstructions on the benefit manager device 106 and/or an additionaldevice.

In some embodiments, at least some of the functionality of the orderprocessing device 102 may be included in the benefit manager device 106.The order processing device 102 may be in a client-server relationshipwith the benefit manager device 106, a peer-to-peer relationship withthe benefit manager device 106, or in a different type of relationshipwith the benefit manager device 106.

The order processing device 102 and/or the benefit manager device 106may be in communication directly (e.g., through local storage) and/orthrough the network 104 (e.g., in a cloud configuration or software as aservice) with a database 108 (e.g., as may be retained in memory orotherwise). The database 108 may store order data 110, member data 112,claims data 114, drug data 116, prescription data 118, and/or plansponsor data 120. Other data may be stored in the database 108.

The order data 110 may include data related to the order ofprescriptions including the type (e.g., drug name and strength) andquantity of each prescription in a prescription order. The order data110 may also include data used for completion of the prescription, suchas prescription materials. In general, prescription materials are a typeof order materials that include an electronic copy of informationregarding the prescription drug for inclusion with or otherwise inconjunction with the fulfilled prescription. The prescription materialsmay include electronic information regarding drug interaction warnings,recommended usage, possible side effects, expiration date, date ofprescribing, or the like. The order data 110 may be used by a highvolume fulfillment center to fulfill a pharmacy order.

In some embodiments, the order data 110 includes verificationinformation associated with fulfillment of the prescription in thepharmacy. For example, the order data 110 may include videos and/orimages taken of (i) the prescription drug prior to dispensing, duringdispensing, and/or after dispensing, (ii) the prescription container(e.g., a prescription bottle and sealing lid) used to contain theprescription drug prior to dispensing, during dispensing, and/or afterdispensing, (iii) the packaging and/or packaging materials used to shipor otherwise deliver the prescription drug prior to dispensing, duringdispensing, and/or after dispensing, and/or (iv) the fulfillment processwithin the pharmacy. Other type of verification information such as barcode data read from pallets used to transport prescriptions within thepharmacy may also be stored as order data 110.

The member data 112 includes information regarding the membersassociated with the benefit manager. Examples of the member data 112include name, address, telephone number, e-mail address, prescriptiondrug history, and the like. The member data 112 may include a plansponsor identifier that identifies the plan sponsor associated with themember and/or a member identifier that identifies the member to the plansponsor. The member data 112 may include a member identifier thatidentifies the plan sponsor associated with the patient and/or a patientidentifier that identifies the patient to the plan sponsor. The memberdata 112 may also include, by way of example, dispensation preferencessuch as type of label, type of cap, message preferences, languagepreferences, or the like.

The member data 112 may be accessed by various devices in the pharmacy,e.g., the high volume fulfillment center, to obtain information utilizedfor fulfillment and shipping of prescription orders. In someembodiments, an external order processing device 102 operated by or onbehalf of a member may have access to at least a portion of the memberdata 112 for review, verification, or other purposes.

In some embodiments, the member data 112 may include information forpersons who are patients of the pharmacy but are not members in abenefit plan being provided by the benefit manager. For example, thesepatients may obtain drug directly from the pharmacy, through a privatelabel service offered by the pharmacy, the high volume fulfillmentcenter, or otherwise. In general, the use of the terms member andpatient may be used interchangeably herein.

The claims data 114 includes information regarding pharmacy claimsadjudicated by the PBM under a drug benefit program provided by the PBMfor one, or more than one, plan sponsors. In general, the claims data114 includes an identification of the client that sponsors the drugbenefit program under which the claim is made, and/or the member thatpurchased the prescription drug giving rise to the claim, theprescription drug that was filled by the pharmacy (e.g., the nationaldrug code number), the dispensing date, generic indicator, GPI number,medication class, the cost of the prescription drug provided under thedrug benefit program, the copay/coinsurance amount, rebate information,and/or member eligibility. Additional information may be included.

In some embodiments, other types of claims beyond prescription drugclaims may be stored in the claims data 114. For example, medicalclaims, dental claims, wellness claims, or other type of healthcare-related claims for members may be stored as a portion of the claimsdata 114.

In some embodiments, the claims data 114 includes claims that identifythe members with whom the claims are associated. In some embodiments,the claims data 114 includes claims that have been de-identified (e.g.,associated with a unique identifier but not with a particular,identifiable member).

The drug data 116 may include drug name (e.g., technical name and/orcommon name), other names by which the drug is known by, activeingredients, an image of the drug (e.g., in pill form), and the like.The drug data 116 may include information associated with a singlemedication or multiple medications.

The prescription data 118 may include information regardingprescriptions that may be issued by prescribers on behalf of patients,who may be members of the drug benefit plan, for example to be filled bya pharmacy. Examples of the prescription data 118 include patient names,medication or treatment (such as lab tests), dosing information, and thelike. The prescriptions may be electronic prescriptions, paperprescriptions that have been scanned, or otherwise. In some embodiments,the dosing information reflects a frequency of use (e.g., once a day,twice a day, before each meal, etc.) and a duration of use (e.g., a fewdays, a week, a few weeks, a month, etc.).

In some embodiments, the order data 110 may be linked to associatedmember data 112, claims data 114, drug data 116, and/or prescriptiondata 118.

The plan sponsor data 120 includes information regarding the plansponsors of the benefit manager. Examples of the plan sponsor data 120include company name, company address, contact name, contact telephonenumber, contact e-mail address, and the like.

The order processing device 102 may direct at least some of theoperations of devices 122-144, recited above. In some embodiments,operations performed by one of these devices 122-144 may be performedsequentially, or in parallel with the operations of another device asmay be coordinated by the order processing device 102. In someembodiments, the order processing device 102 tracks a prescription withthe pharmacy based on operations performed by one or more of the devices122-144.

In some embodiments, the system 100 may transport prescription drugcontainers (e.g., between one or more than one of the devices 122-144 inthe high volume fulfillment center) by use of pallets. The pallet sizingand pucking device 122 may configure pucks in a pallet. A pallet may bea transport structure for a number of prescription containers, and mayinclude a number of cavities. A puck may be placed in one or more thanone of the cavities in a pallet by the pallet sizing and pucking device122. A puck may include a receptacle sized and shaped to receive aprescription container. Such containers may be supported by the pucksduring carriage in the pallet. Different pucks may have differentlysized and shaped receptacles to accommodate containers of differingsizes, as may be appropriate for different prescriptions.

The arrangement of pucks in a pallet may be determined by the orderprocessing device 102 based on prescriptions which the order processingdevice 102 decides to launch. In general, prescription orders in theorder database 110 reside in one or more than one queues, and aregenerally launched in a first-in-first-out order. However, the orderprocessing device 102 may use logic and a variety of factors todetermine when and how prescriptions are to be launched. For example,some non-limiting factors which may alter the first-in-first-out orderof launching prescriptions in a pharmacy include the age of the order,whether the order required an outreach to a physician or some otherintervention, whether there are any performance guarantees with plansponsors or members, the available inventory of a given pharmaceuticalin view of existing prescriptions already launched which will requirethat pharmaceutical, the zip code to which the order will be shipped,the workload and volume of various parts of the pharmacy, whether validpaperwork for the order has been received, and/or similar orders for thesame pharmaceutical that are already to be launched. The logic may beimplemented directly in the pallet sizing and pucking device 122, in theorder processing device 102, in both devices 102, 122, or otherwise.Once a prescription is set to be launched, a puck suitable for theappropriate size of container for that prescription may be positioned ina pallet by a robotic arm or pickers. The pallet sizing and puckingdevice 122 may launch a pallet once pucks have been configured in thepallet.

The loading device 124 may load prescription containers into the puckson a pallet by a robotic arm, pick and place mechanism, or the like. Inone embodiment, the loading device 108 has robotic arms or pickers tograsp a prescription container and move it to and from a pallet or apuck. The loading device 124 may also print a label which is appropriatefor a container that is to be loaded onto the pallet, and apply thelabel to the container. The pallet may be located on a conveyor assemblyduring these operations, e.g., at the high volume fulfillment center.

The inspect device 126 may verify that containers in a pallet arecorrectly labeled and in the correct spot on the pallet. The inspectdevice 126 may scan the label on one or more than one container on thepallet. Labels of containers may be scanned or imaged in full or in partby the inspect device 126. Such imaging may occur after the containerhas been lifted out of its puck by a robotic arm, picker, or the like,or may be otherwise scanned or imaged while retained in the puck. Insome embodiments, images and/or video captured by the inspect device 126may be stored in the database 108 as order data 110.

The unit of use device 128 may temporarily store, monitor, label and/ordispense unit of use products. In general, unit of use products areprescription drug products that may be delivered to a patient or memberwithout being repackaged at the pharmacy. These products may includepills in a container, pills in a blister pack, inhalers, and the like.Prescription drug products dispensed by the unit of use device 128 maybe packaged individually or collectively for shipping, or may be shippedin combination with other prescription drugs dispenses by other devicesin the high volume fulfillment center.

The automated dispensing device 130 may include one or more than onedevices that dispense prescription drugs or pharmaceuticals intoprescription containers in accordance with one or multiple prescriptionorders. In general, the automated dispensing device 130 may includemechanical and electronic components with, in some embodiments, softwareand/or logic to facilitate pharmaceutical dispensing that wouldotherwise be performed in a manual fashion by a pharmacist and/orpharmacist technician. For example, the automated dispensing device 130may include high volume fillers that fill a number of prescription drugtypes at a rapid rate and blister pack machines that dispense and packdrugs into a blister pack. Prescription drugs dispensed by the automateddispensing devices 130 may be packaged individually or collectively forshipping, or may be shipped in combination with other prescription drugsdispenses by other devices in the high volume fulfillment center.

The manual fulfillment device 132 may provide for manually fulfillmentof prescriptions. For example, the manual fulfillment device 132 mayreceive or obtain a container and enable fulfillment of the container bya pharmacist or pharmacy technician. In some embodiments, the manualfulfillment device 132 provides the filled container to another devicein the system 100 to be joined with other containers in a prescriptionorder for a patient or member. In general, a manual fulfillment mayinclude operations at least partially performed by a pharmacist orpharmacy technician. For example, a person may retrieve a supply of theprescribed drug, may make an observation, may count out a prescribedquantity of drugs and place them into a prescription container, or thelike. Some portions of the manual fulfillment process may be automatedby use of a machine. For example, counting of capsules, tablets, orpills may be at least partially automated (e.g., through use of a pillcounter). Prescription drugs dispensed by the manual fulfillment device132 may be packaged individually or collectively for shipping, or may beshipped in combination with other prescription drugs dispenses by otherdevices in the high volume fulfillment center.

The review device 134 may process prescription containers to be reviewedby a pharmacist for proper pill count, exception handling, prescriptionverification, and the like. Fulfilled prescriptions may be manuallyreviewed and/or verified by a pharmacist, as may be required by state orlocal law. A pharmacist or other licensed pharmacy person who maydispense certain drugs in compliance with local and/or other laws mayoperate the review device 134 and visually inspect a prescriptioncontainer that has been filled with a prescription drug. The pharmacistmay review, verify, and/or evaluate drug quantity, drug strength, and/ordrug interaction concerns, or otherwise perform pharmacist services. Thepharmacist may also handle containers which have been flagged as anexception, such as containers with unreadable labels, containers forwhich the associated prescription order has been cancelled, containerswith defects, and the like.

The imaging device 136 may image containers once they have been filledwith pharmaceuticals. The imaging device 136 may measure the fill heightof the pharmaceuticals in the container based on the obtained image todetermine if the container is filled to the correct height given thetype of pharmaceutical and the number of pills in the prescription.Images of the pills in the container may also be obtained to detect thesize of the pills themselves and markings thereon. The images may betransmitted to the order processing device 102, and/or stored in thedatabase 110 as part of the order data 110.

The cap device 138 may be used to cap or otherwise seal a prescriptioncontainer. In some embodiments, the cap device 138 may secure aprescription container with a type of cap in accordance with a patientpreference (e.g., a preference regarding child resistance), a plansponsor preference, a prescriber preference, or the like. The cap device138 may also etch a message into the cap, although this process may beperformed by a subsequent device in the high volume fulfillment center.

The accumulation device 140 accumulates various containers ofprescription drugs in a prescription order. The accumulation device 140may accumulate prescription containers from various devices or areas ofthe pharmacy. For example, the accumulation device 140 may accumulateprescription containers from the unit of use device 128, the automateddispensing device 130, the manual fulfillment device 132, and the reviewdevice 134, at the high volume fulfillment center. The accumulationdevice 140 may be used to group the prescription containers prior toshipment to the member or otherwise.

The packing device 142 packages a prescription order in preparation forshipping the order. The packing device 142 may box, bag, or otherwisepackage the fulfilled prescription order for delivery. The packingdevice 142 may further place inserts into the packaging. For example,bulk prescription orders may be shipped in a box, while otherprescription orders may be shipped in a bag which may be a wrap sealbag. The packing device 142 may label the box or bag with the addressand a recipient's name. The packing device 142 may sort the box or bagfor mailing in an efficient manner (e.g., sort by delivery address). Thepacking device 142 may include ice or temperature sensitive elements forprescriptions which are to be kept within a temperature range duringshipping in order to retain efficacy or otherwise. The ultimate packagemay then be shipped through postal mail, through a mail order deliveryservice that ships via group and/or air (e.g., UPS, FedEx, or DHL),through delivery service, through a locker box at a shipping site (e.g.,Amazon locker or a PO Box), or otherwise.

The unit of use packing device 144 packages a unit of use prescriptionorder in preparation for shipping the order. The unit of use packingdevice 144 may include manual scanning of containers to be bagged forshipping to verify each container in the order.

While the system 100 in FIG. 1 is shown to include single devices 102,106, 122-144 multiple devices may be used. The devices 102, 106, 122-144may be the same type or model of device or may be different device typesor models. When multiple devices are present, the multiple devices maybe of the same device type or models or may be a different device typeor model. The types of devices 102, 106, 122-144 shown in FIG. 1 areexample devices. In other configurations of the system 100, lesser,additional, or different types of devices may be included.

Moreover, the system 100 shows a single network 104; however, multiplenetworks can be used. The multiple networks may communicate in serieswith each other to link the devices 102, 106, 122-144 or in parallel tolink the devices 102, 106, 122-144. Multiple devices may shareprocessing and/or memory resources. The devices 102, 106, 122-144 may belocated in the same area or in different locations. For example, thedevices 102, 106, 122-144 may be located in a building or set ofadjoining buildings. The devices 102, 106, 122-144 may be interconnected(e.g. by conveyors), networked, and/or otherwise in contact with oneanother or integrated with one another, e.g., at the high volumefulfillment center. In addition, the functionality of a device may besplit among a number of discrete devices and/or combined with otherdevices.

FIG. 2 illustrates the order processing device 102, according to anexample embodiment. The order processing device 102 may be used by oneor more than one operator to generate prescription orders, make routingdecisions, make prescription order consolidation decisions, and/or vieworder status and other order related information. For example, theprescription order may be comprised of order components. The orderprocessing device 102 may receive instructions to fulfill an orderwithout operator intervention. An order component may include aprescription drug fulfilled by use of a container through the system100. The order processing device 102 may direct an order component tothe manual fulfillment device 132 and/or to the review device 134, anddirect other components to the automated dispensing device 130. Theorder processing device 102 may direct order components to theaccumulation device 140 for aggregation before shipping. The orderprocessing device 102 may direct the order components directly to thepacking device 142 if the prescription order does not requireaccumulation from various areas of the pharmacy for completion. Theorder processing device 102 may be deployed in the system 100, or mayotherwise be used.

The order processing device 102 may include an order verificationsubsystem 202, an order control subsystem 204, and/or an order trackingsubsystem 206. Other subsystems may also be included in the orderprocessing device 102.

The order verification subsystem 202 may communicate with the benefitmanager device 106 to, verify the eligibility of the member, review theformulary to determine appropriate co-pay, coinsurance, and deductiblefor the prescription drug, and/or perform a DUR. Other communicationsbetween the order verification subsystem 202 and the benefit managerdevice 106 may be performed for a variety of purposes.

The order control subsystem 204 controls various movements of thecontainers and/or pallets along with various filling functions duringtheir progression through the system 100. In some embodiments, the ordercontrol subsystem 204 may identify the prescribed drug in one or morethan one prescription order as capable of being fulfilled by theautomated dispensing device 130. The order control subsystem 204 maydetermine which prescriptions are to be launched, and may determine thata pallet of automated-fill containers is to be launched. The ordercontrol subsystem 204 may determine that an automated-fill prescriptionof a specific pharmaceutical is to be launched, and may examine a queueof orders awaiting fulfillment for other prescription orders which willbe filled with the same pharmaceutical. The order control subsystem 204may then launch orders with similar automated-fill pharmaceutical needstogether in a pallet to the automated dispensing device 130. As thedevices 122-144 may be interconnected by a system of conveyors or othercontainer movement systems, the order control subsystem 204 may controlvarious conveyors to deliver the pallet from the loading device 124 tothe manual fulfillment device 132, for example.

The order tracking subsystem 206 may track a prescription order as itprogresses (or stops) toward fulfillment. The order tracking subsystem206 may track, record and/or update order history, order status or thelike. The order tracking subsystem 206 may store data locally (e.g., ina memory) or as a portion of the order data 110 stored in the database108.

FIG. 3 illustrates a pallet 302, according to an example embodiment. Thepallet 302 may be used in the system 100 of FIG. 1 (e.g., by theautomated dispensing device 122), or may be otherwise used. The pallet302 may be a transport structure for a number of prescription containers304, and may include a number of cavities 306. While the pallet 302 isshown to include 25 cavities in a five by five cavity row/columnconfiguration, other numbers of categories and/or cavity configurationsof varying shapes, size, and/or dimensions may be used. In someembodiments, other carriers beyond the pallet 302 and/or no carrier maybe used to move containers or groups of containers through the system100 by the conveyors, to the devices 122-144, or otherwise.

The pallet 302 may retain one or more than one container 304. Acontainer 304 is generally cylindrical and may be of one or a variety ofsizes utilized by a pharmacy for fulfillment of a prescription. Forexample, a pharmacy may have two different sized containers or threedifferent sized containers. Any number of different sized containers maybe used with the pallet 302. While the container 304 is generallydenoted as being used with the pallet 302, the containers 304 mayotherwise be used in the system 100 or in a different system. Shapesbeyond cylindrical shapes may be used for the containers 304.

The automated dispensing device 130 may be used, for example, todispense commonly prescribed drugs in an automatic or semiautomaticmethod into containers. Drugs may be dispensed in connection withfilling one or more than one prescriptions (or portions ofprescriptions). Drugs dispensed by the automated dispensing device 130may be tablets, pills, capsules, caplets, or other types of drugssuitable for dispensing by the automated dispensing device 130.

FIG. 4 illustrates an automated dispensing device 130, according to anexample embodiment. The automated dispensing device 130 enablesdispensing of a number of different types of pharmaceuticals in anautomatic or semiautomatic manner. The automated dispensing device 130includes a filling cabinet 402, a prefill assembly 404, and a palletassembly 406. The filling cabinet 402 stores pharmaceuticals to bedispensed into containers via the prefill assembly 404 and dispensesmeasured quantities of pharmaceuticals into the prefill assembly 404.The prefill assembly 404 stores the measured quantities ofpharmaceuticals and dispenses the measured quantities of pharmaceuticalsreceived from the filling cabinet 402 into containers 304 on a pallet302 while in the pallet assembly 406.

A pallet conveyor 412 may transport the pallets 302 through some or allof the devices within the system 100, such as the automated dispensingdevice 130. The pallet assembly 406 receives the pallets 302 via thepallet conveyor 412 and moves the pallets 302 within the pallet assembly406 such that pharmaceuticals dispensed by the automated dispensingsubsystem 204 are dispensed into the containers 304 on the pallet 302.Although pallets are generally described herein as employed to move agroup of containers through the system 100, trays or other types ofcarriers may, in some embodiments, be employed to move a group ofcontainers through the system 100.

The filling cabinet 402 may be physically housed above the prefillassembly 404 and the pallet assembly 406. For example, the fillingcabinet 402 may be located on a first, upper floor and the prefillassembly 404 and the pallet assembly 406 may be located on a second,lower floor below the filling cabinet 402. These components may beotherwise positioned. For example, some portion of the filling cabinet402 may extend below the first floor.

FIG. 4 also illustrates a spill detection system 420, according to anexample embodiment. As shown in FIG. 4, the spill detection system 420has been installed within and through the pallet assembly 406 of theautomated dispensing device 130. For ease of reference herein, the spilldetection system 420 will be discussed in the context of itsinstallation and use with the automated dispensing device 130. However,the spill detection system 420 may be used in connection with one ormore than one of devices 122-144, in connection with different automatedor semi-automated dispensing devices, elsewhere within or external to apharmacy or the high volume fulfillment center, or otherwise.

Additionally, as shown in FIG. 4, the spill detection system 420 isillustrated as being positioned adjacent to the pallet conveyor 412within the pallet assembly 406. However, the spill detection system 420could be installed so as to extend around or below pallet conveyor 412,or be positioned elsewhere within or around the automated dispensingdevice 130. As most spills are likely to occur at or beneath the prefillassembly 404, the spill detection system 420 is shown herein beneath theprefill assembly 404. However, this is merely a non-limiting exampleembodiment of an implementation of the spill detection system 420.

FIG. 5 illustrates a side elevation view of the prefill assembly 404,the pallet assembly 406, and the spill detection system 420 of FIG. 4.The spill detection system 420 may include a mirror portion 502 and acamera portion 504. FIG. 6 illustrates a top plan view of the palletassembly 406, in which example embodiments of the mirror portion 502 andthe camera portion 504 can be seen in additional detail. FIG. 7illustrates a top plan view of the spill detection system 420 removedfrom the context of the pallet assembly 406, according to an exampleembodiment.

As shown in FIG. 6, the pallet assembly 406 may include a palletassembly frame 602 to provide support to the pallet assembly 406,including the pallet conveyor 412 and an x-y movement apparatus 604. Thex-y movement apparatus 604 may alter the position of the pallet 302within the pallet assembly 406 of the automated dispensing device 130.The x-y movement apparatus 604 may include an x-component 606 and ay-component 608. The x-component 606, in operation, may move a pallet302 in a direction perpendicular to the pallet conveyor 412. Thex-component 606 may include an x-axis support arm 610 that supports thepallet 302 as it moves within the pallet assembly 406 and an x-componentmotor 614 that actuates the x-component 606 of the x-y movementapparatus 604. The y-component 608, in operation, may move a pallet 302in a direction parallel to the pallet conveyor 412. The y-component 608,may include a y-axis support arm 612 that supports the pallet 302 as itmoves within the pallet assembly 406 and a y-component motor 616 thatactuates the y-component 608 of the x-y movement apparatus 604. The x-ymovement apparatus 604 may engage and move the pallet 302 within thepallet assembly 406 of the automated dispensing device 130 such that adesired container 304 in a pallet 302 is moved to an appropriateposition below the prefill assembly 404 for filling the desiredcontainer 304 with a desired pharmaceutical.

The pallet assembly 406 may also include a lift apparatus 618. The liftapparatus 618 may engage the pallet 302 and lift it such that a desiredcontainer 304 on the pallet 302 is aligned to receive a pharmaceuticalfrom the prefill assembly 404. In an example, the desired container 304may be positioned directly (or substantially directly) below the buffertube opening of a buffer tube in the prefill assembly 404. The buffertube may be in communication with a bin in the filling cabinet 402 whichholds the desired pharmaceutical to be dispensed into the desiredcontainer 304. Upon releasing pharmaceuticals into the desired container304, some of the pharmaceuticals may spill.

As can be seen in FIG. 6, but as better seen in FIG. 7, the mirrorportion 502 of the spill detection system 420 may include a mirror 620.The camera portion 504 may include a camera 622 and a light panel 624.The camera 622 may be in communication with a control unit 626. Themirror 620 may be a concave mirror. In an example, the concave mirrormay be approximately parabolic. In an example embodiment, the camera 622may be a COGNEX® In-Sight 7000 Series Vision System camera. In anotherexample embodiment, the camera 622 may be COGNEX® In-Sight 7402-01camera. In an example, the camera 622 can be a grayscale camera, whichmay produce a full image of 1280×1024 pixels. The camera 622 may be amedium-to-high resolution camera, as that term is understood in the art.In an example embodiment, the camera 622 may be capable of capturingapproximately thirty to ninety images per second, or one image aboutevery ten to thirty milliseconds. In an example, the camera 622 cancapture and compare successive images to detect movement of a spilledpharmaceutical, e.g., a pharmaceutical product, for example, a pill, atablet, a capsule, a gel capsule, and the like.

Between the mirror portion 502 and the camera portion 504 is a fillingarea 702 above which a container 304 may be filled with apharmaceutical. The filling area 702 is therefore an area in which aspill may occur. The mirror 620 may extend the entire width of thefilling area 702. In an example embodiment, the mirror 620 can extendpast the width of the filling area 702 to cover the width of an area inwhich a prescription may spill. The mirror 620 may be a polishedstainless steel mirror. The mirror 620 is curved so that an image alongthe upper line 711 is reflected along line 712 to the camera 622.Likewise, an image along the lower edge of the filling area 702 isreflected by the mirror portion 502 to and edge of the camera 622. Themirror 620 can also be curved so that it reflects an image at the top ofthe viewing area to a top of bottom edge of the camera. The camera 622may therefore be aimed at the mirror 620 across the filling area 702.The camera 622 is positioned at the center of the filling area 702 andis positioned to point at the center of the mirror 702. The light panel624 may emit light toward the mirror 620, which reflects off of themirror 620 back toward the camera 622. However, the immediate field ofview 704 of the camera 622 may not cover a portion of the filling area702, as shown in FIG. 7. The camera 622 may therefore be focused on thereflection of filling area 702 in the mirror 620, creating a distantfield of view which may be coextensive with filling area 702. In anexample embodiment, the camera 622 may be focused on the reflection ofcamera portion 504 in mirror 620.

FIG. 8 illustrates a front elevation view of the camera portion 504,according to an example embodiment. The camera 622 may include a lens802. The light panel 624 may include one or more than one light source804 and a light diffuser 806. The lens 802 may be a telecentric lens.Alternatively, or in addition, the concave curve of the mirror 620 mayapproximate the use of a telecentric lens on camera 622, according to anexample embodiment. As illustrated in FIG. 8, only the lens 802 of thecamera 622 is visible. The camera is shown in phantom because it may bepositioned behind the light panel 624. In such an example embodiment,the lens 802 may extend through a hole in the light panel 624. In adifferent example embodiment, the camera 622 may be positioned in frontof the light panel 624.

The one or more than one light source 804 (referred to hereinafter forease of reference as light sources 804) is shown in phantom in FIG. 8due to their positioning behind the light diffuser 806. The lightsources 804 may be elongated fluorescent bulbs, as illustrated in FIG.8. However, any desirable type of light source may be used. Asnon-limiting examples, the light sources 804 may be LED lights,fluorescent lights, incandescent lights, or combinations thereof.Additionally, although the light sources 804 are illustrated withspecific sizes, in specific orientations and arrangements in FIG. 8, itwill be understood that this is not limiting. The light sources 804 maybe arranged in any desirable combination, position, and arrangement. Thelight diffuser 806 may be a translucent material which spreads andsoftens light passing through the light diffuser 806 from the lightsources 804.

The optical subsystem, e.g., the mirror 620 and the camera 622, operateto image a pharmaceutical product that has spilled and is beneath thefilling area of the prefill assembly 404 and the container carrier,e.g., pallet and other carrier.

FIG. 9 illustrates the control unit 626, according to an exampleembodiment. The control unit 626 may be deployed in the spill detectionsystem 420, or may otherwise be used. The control unit 626 may operateat the direction of the order processing device 102, or may be integralwith the order processing device or otherwise. The control unit 626 mayinclude a filling status subsystem 902 and an image analysis subsystem904. The control unit 626 may be responsible for enabling the spilldetection system 420, for example when a pallet 302 is positioned forfilling. The control unit 626 may also direct the camera 622 to captureimages, and may analyze the captured images for any possible spills. Thecontrol unit 626 may be communicatively coupled to one or more than onecomponent in the camera portion 504, such as the camera 622 and thelight sources 804. The control unit 626 may control the light sources804 to illuminate the filling area 702 when a filling operation is beingconducted.

The filing status subsystem 902 may enable the control unit 626 todetermine whether and when a pallet 302 has been moved into or above thefilling area 702 for filling. The filling status subsystem 902 may thensignal the components of the camera portion 504 to enable imaging. Theimage analysis subsystem 904 may analyze captured images from the camera622 to determine whether a spill has occurred. In an example, the imageanalysis subsystem 904 may compare successive images captured by thecamera 622 to determine a change in the images to determine whether apharmaceutical product has been filled, e.g., during filing apharmaceutical order in the high volume fulfillment center.

FIG. 10 illustrates an example filling status subsystem 902 that may bedeployed in the control unit 626, or may be otherwise deployed inanother system. One or more modules are communicatively coupled andincluded in the filling status subsystem 902 to enable the fillingstatus subsystem 902 to identify whether and when a pallet 302 has beenmoved into or above the filling area 702 for filling, and subsequentlyenable the components of the camera portion 504. The modules of thefilling status subsystem 802 that may be included are a communicationmodule 1002, an imaging activation module 1004, and an imaging module1006. Other modules may also be included.

In some embodiments, the modules of the filling status subsystem 902 maybe distributed so that some of the modules are deployed in other deviceswithin the pharmacy. In one embodiment, the modules are deployed inmemory and executed by a processor coupled to the memory. Thefunctionality contained within the modules 1002-1006 may be combinedinto a lesser number of modules, further divided among a greater numberof modules, or redistributed among existing modules. Otherconfigurations including the functionality of the modules 1002-1006 maybe used.

The communication module 1002 may manage communication with, forexample, the pallet assembly 406 of automated dispensing device 130.Thereby, the communication module 1002 may receive a signal from theautomated dispensing device 130 when the pallet assembly 406 has moved apallet 302 into the filling area 702. The imaging activation module 1004may send a signal to the camera portion 504 to enable the camera 622 andlight sources 804 of light panel 624. The imaging module 1006 mayinstruct the camera 622 to begin capturing images of the filling area702.

FIG. 11 illustrates an example image analysis subsystem 904 that may bedeployed in the control unit 626, or may be otherwise deployed inanother system. One or more modules are communicatively coupled andincluded in the image analysis subsystem 904. The modules of the imageanalysis subsystem 904 that may be included are an object detectionmodule 1102, an image storage module 1104, an image comparison module1106 and/or an analysis module 1108. Other modules may also be included.

In some embodiments, the modules of the image analysis subsystem 904 maybe distributed so that some of the modules are deployed in other deviceswithin the pharmacy. In one embodiment, the modules are deployed inmemory and executed by a processor coupled to the memory. Thefunctionality contained within the modules 1102-1108 may be combinedinto a lesser number of modules, further divided among a greater numberof modules, or redistributed among existing modules. Otherconfigurations including the functionality of the modules 1102-1108 maybe used.

The object detection module 1102 may be in communication with camera622, and may receive an image captured by camera 622. The objectdetection module 1102 may make a determination as to whether an object,e.g., a blob, is visible in the received image captured by the camera622. In an example embodiment, such determination may be made bylocating any artifacts in the captured image above or below apredetermined number of pixels. However, alternative techniques fordetecting an object in an acquired image may also be used, such as basedon a comparison of a captured image to a baseline image stored in anelectronic memory accessible by the image analysis subsystem 904, as anon-limiting example. Such a comparison may utilize the functionality ofthe image comparison module 1106, and/or the object analysis module1108, discussed below.

The object detection module 1102 may be a blob detection module thatuses mathematical methods that are aimed at detecting regions in adigital image that differ in properties, such as brightness or color,compared to areas surrounding those regions. A blob is a region of adigital image in which some properties are constant or vary within aprescribed range of values. In an example embodiment, all the points ina blob can be considered in some sense to be similar to each other. Blobdetection can be performed by using several different methods including:(1) differential methods, which are based on derivatives of the functionwith respect to position (e.g., a pharmaceutical falling into the fieldof view, in the Z direction), and (2) methods based on local extrema,which are based on finding the local maxima and minima of the function(significant changes from one pixel to an adjacent pixel at such a sizethat is consistent with a pharmaceutical). Other methods may be used. Ablob may, in some embodiments, be defined as an area of connected pixelsof similar intensity or color, which appear in images from the camera622 when a pharmaceutical drops beneath the fill area. It will berecognized that the more pixels that are connected, the larger the blobarea that can be detected in the image. The use of the light source 624illuminates the field of view. As a result of such usage spill darkspots, e.g., the blobs, appear in the images.

The image storage module 1104 may be in communication with an electronicmemory, for storing and/or accessing captured images in the electronicmemory. The image storage module 1104 may track and store an image or aseries of consecutive captured images when an object is detectedtherein. The image storage module 1104 may therefore track whether anobject was present on any stored previous image. The image storagemodule 1104 may also clear stored images from the electronic memory whenit is determined that such images do not show a spill.

Image comparison module 1106 may receive images for comparison to oneanother. In an example embodiment, image comparison module 1106 mayreceive a captured image from camera 622 or object detection module1102, and compare the captured image with a stored image received fromimage storage module 1104. The image comparison module 1106 may compareany objects located by the object detection module 1102 in the capturedimage with any object previously identified by the object detectionmodule 1102 in a stored image, to determine if the position of theobject has moved from one image to the other. In an example embodiment,the image comparison module 1106 may utilize data from the objectanalysis module 1108, discussed below, to determine by how much anobject has moved, and/or whether the object has changed size and/orshape.

Object analysis module 1108 may receive a captured image and/or a storedimage, and may analyze any objects identified in such image. The objectanalysis module 1108 may make a pixel by pixel comparison of an image,or may utilize other pixel analysis techniques as are known in the art.The object analysis module 1108 may provide information regarding thesize, shape, and/or position of the object to the image comparisonmodule 1106.

Object detection may be performed to detect a miss-packagedpharmaceutical. First, an image from the camera 622 is captured by theobject detection module 1102 that represents the entire area and achange in the image is determined and stored (e.g., the position andsize of anything that could be a pharmaceutical) by the image comparisonmodule 1106. These areas of change are then re-analyzed locally forcontrast and size by the image comparison module 1106. The imagecomparison module 1106 then compares over consecutive images. A falsepositive analysis is performed by the analysis model 1108. Areas ofchange that are too close to each other in consecutive images areignored by the analysis model 1108 as false positives. Such falsedetection by the analysis model 1108 may be due to dust, flying orcrawling insects, or a dark spot on the mirror/backlight. If an area ofchange in the image is accepted as not a false positive, then the imageis stored by the image storage module 1104 as a detection occurrence.When detection occurs by the analysis model 1108 on consecutive images,the size (pixels) and location are stored by the image storage module1104. Then consecutive images are analyzed for a same area of interestby the image comparison module 1106. In an example embodiment, more thanthree images are analyzed by the image comparison module 1106 (as may bedeployed in in the camera 622, the control unit 626, or otherwise). Inan example embodiment, four or more images are analyzed. The subsequentimages are analyzed and the maximum count and maximum pixel area forthese images is added to an accumulator. This multiple images can beused to minimize the multiple counting of pharmaceutical as they areseen in multiple image frames. The accumulator runs for a period of timeequivalent to the polling interval of the control unit 626, and is thenreset.

FIG. 12 illustrates a method 1200 for spill detection, according to anexample embodiment. The method 1200 may be performed by the spilldetection system 420 as instructed by control unit 626, or may beotherwise performed.

At block 1205, a determination is made (e.g., by the filling statussubsystem 902) of whether a pallet 302 has been moved into the fillingarea 702 for filling. If not, the method 1200 repeats these operationsuntil a pallet 302 has been moved into the filling area 702. Once apallet has been moved into the filling area 702, as discussed above, acamera portion 504 is activated (e.g., the imaging activation module1004) and causes the camera 622 (e.g., by the image capturing module1006) to begin capturing images. At block 1210, an image is acquired bythe camera 622. At block 1215, a determination is made (e.g., by theobject detection module 1102) whether an object is present in theacquired image. At block 1220, where no objects are detected, the method1200 advances to block 1225 where the electronic memory (e.g., caused bythe image storage module 1104) discards any stored images, along withthe acquired image. In some embodiments, stored images may be retaineduntil a predetermined number of consecutive image captures do notcontain an object. The method then returns back to block 1205.

However, at block 1120, when an object is detected, a determination ismade (e.g., by the image storage module 1104) whether there are anypreviously stored consecutive images on which an object appears. Wherethe previous image or consecutive images did not contain objects, thecaptured image is stored in electronic memory as a possible detectionoccurrence (e.g., by the image storage module 1104) at block 1235. Themethod then returns to block 1205. However, at block 1230, wheredetermination is made that there is at least one previous consecutiveimage in storage with a potential object, the method advances to block1240.

At block 1240, a comparison of the position of an object in the acquiredimage to the position of an object in one or more of the previousconsecutive image(s) is made (e.g., by the image comparison module1106). In some embodiments, a comparison may be made betweennon-sequential images, such as when an object appears in an image, thenis not present in one or more images, and then reappears in a subsequentimage. Such an event could occur, for example, if a spilledpharmaceutical appears in frame, then passes behind a piece of hardwaresuch as x-y movement apparatus 604, and then reappears toward the bottomof the frame after passing behind the x-y movement apparatus 604. Atblock 1245, a determination is made (e.g., by the image comparisonmodule 1106) as to whether the object in the acquired image and theobject in one or more of the previous consecutive image(s) is within apredetermined range of distances from one another. In an exampleembodiment, the predetermined distance may be an expected range that apill would fall due to gravity. In another example embodiment, thepredetermined distance may be a predetermined number of pixels.

If an object, e.g., a blob in blob detection, has not moved within thepredetermined range of distances from the previous image(s) to theacquired image, the method reverts to block 1225 any stored images,along with the acquired image are discarded (e.g., by the image storagemodule 1104 as caused by the electronic memory). The method 1200 thenreturns back to block 1205. However, where an object has moved withinthe predetermined range of distances from the previous image(s) to theacquired image, the method advances to block 1250. At block 1250, anobject in the acquired image and/or an object in a previous consecutiveimage may be analyzed (e.g., by the object analysis module 1108) todetermine whether the pixel count of such object is within apredetermined range. In an example embodiment, the predetermined pixelcount range may correspond to an expected range of sizes of a pill orother pharmaceutical product. In another example embodiment, the pixelrange may be between one and eighteen pixels. If no object is within thepredetermined pixel count range, the method 1200 reverts to block 1225discard any stored images, along with the acquired image are discarded(e.g., as caused by the electronic memory from the image storage module1104). However, where an object is within the predetermined pixel countrange, the method advances to block 1255 in which a spill is detected.

The operations in method 1200 need not be performed in the orderdescribed above. As a non-limiting example, the comparison of objectpositions from image to consecutive image may occur after thedetermination of object pixel count. Additionally, a spill may not bedetected at block 1255 until a predetermined number of consecutiveimages are determined to contain an object that is within apredetermined pixel count range, and which the object has moved adistance that is within a predetermined range from each of thepredetermined number of images to the next image. In an exampleembodiment, the predetermined number of consecutive images may begreater than three images, four images, greater than eight images orgreater than twelve images.

FIG. 13 illustrates a side elevation view of a pallet mount 1302,according to an example embodiment. As shown, a pallet mount 1302 may bepositioned on the x-y movement apparatus 604, and a pallet 302 may beplaced on the pallet mount 1302 for movement within the filling area702. The side elevation view of FIG. 13 may be the angle at which thecamera 622 views the pallet mount 1302 when the pallet mount 1302 movesa pallet 302 in the filling area 702 for filling. Pallet mount 1302 mayinclude first and second legs 1304, 1306 which define a space 1308 therebetween. By including space 1308 between legs 1304, 1306, camera 622 maybe able to image a spill that occurs and would be seen in the space1308.

FIG. 14 shows a block diagram of a machine in the example form of acomputer system 1400 within which a set of instructions may be executedcausing the machine to perform any one or more of the methods,processes, operations, or methodologies discussed herein. The device102, 106, 122-144, 420, for example, may include the functionality ofthe one or more computer systems 1400.

In an example embodiment, the machine operates as a standalone device ormay be connected (e.g., networked) to other machines. In a networkeddeployment, the machine may operate in the capacity of a server or aclient machine in server-client network environment, or as a peermachine in a peer-to-peer (or distributed) network environment. Themachine may be a server computer, a client computer, a personal computer(PC), a tablet PC, a gaming device, a set-top box (STB), a PersonalDigital Assistant (PDA), a cellular telephone, a web appliance, anetwork router, switch or bridge, or any machine capable of executing aset of instructions (sequential or otherwise) that specify actions to betaken by that machine. Further, while only a single machine isillustrated, the term “machine” shall also be taken to include anycollection of machines that individually or jointly execute a set (ormultiple sets) of instructions to perform any one or more of themethodologies discussed herein.

The example computer system 1400 includes a processor 1402 (e.g., acentral processing unit (CPU) a graphics processing unit (GPU) or both),a main memory 1404 and a static memory 1406, which communicate with eachother via a bus 1408. The computer system 1400 further includes a videodisplay unit 1410 (e.g., a liquid crystal display (LCD) or a cathode raytube (CRT)). The computer system 1400 also includes an alphanumericinput device 1412 (e.g., a keyboard), a cursor control device 1414(e.g., a mouse), a drive unit 1416, a signal generation device 1418(e.g., a speaker) and a network interface device 1420.

The drive unit 1416 includes a computer-readable medium 1422 on which isstored one or more sets of instructions (e.g., software 1424) embodyingany one or more of the methodologies or functions described herein. Thesoftware 1424 may also reside, completely or at least partially, withinthe main memory 1404 and/or within the processor 1402 during executionthereof by the computer system 1400, the main memory 1404 and theprocessor 1402 also constituting computer-readable media.

The software 1424 may further be transmitted or received over a network1426 via the network interface device 1420.

While the computer-readable medium 1422 is shown in an exampleembodiment to be a single medium, the term “computer-readable medium”should be taken to include a single medium or multiple media (e.g., acentralized or distributed database, and/or associated caches andservers) that store the one or more sets of instructions. The term“computer-readable medium” shall also be taken to include any mediumthat is capable of storing or encoding a set of instructions forexecution by the machine and that cause the machine to perform any oneor more of the methodologies of the present invention. The term“computer-readable medium” shall accordingly be taken to include, butnot be limited to, solid-state memories, and optical media, and magneticmedia. In some embodiments, the computer-readable medium is anon-transitory computer-readable medium. In other examples, acomputer-readable medium is any medium that satisfies statutoryrequirements and stores instructions for use by a machine.

The term “based on” or using, as used herein, reflects an open-endedterm that can reflect others elements beyond those explicitly recited.

Certain systems, apparatus, applications or processes are describedherein as including a number of modules. A module may be a unit ofdistinct functionality that may be presented in software, hardware, orcombinations thereof. When the functionality of a module is performed inany part through software, the module includes a computer-readablemedium. The modules may be regarded as being communicatively coupled.

The embodiments of the present disclosure generally provide for aplurality of circuits or other electrical devices, which can be used inunits, modules, systems, and subsystems and the like. All references tosuch and the functionality provided by each, are not intended to belimited to encompassing only what is illustrated and described herein.While particular labels may be assigned to the various circuits or otherelectrical devices disclosed, such labels are not intended to limit thescope of operation for the circuits and the other electrical devices.Such circuits and other electrical devices may be combined with eachother and/or separated in any manner based on the particular type ofelectrical/operational implementation that is desired. It is recognizedthat any circuit or other electrical device disclosed herein may includeany number of microprocessors, discrete circuit components, integratedcircuits, memory devices (e.g., FLASH, random access memory (RAM), readonly memory (ROM), electrically programmable read only memory (EPROM),electrically erasable programmable read only memory (EEPROM), or othersuitable variants thereof) and instructions (e.g., software) whichco-act with one another to perform operation(s) disclosed herein. Inaddition, any one or more of the electric devices may be configured toexecute a computer-program that is embodied in a computer readablemedium that is programmed to perform any number of the functions andfeatures as disclosed. The computer readable medium may benon-transitory or in any form readable by a machine or electricalcomponent

The inventive subject matter may be represented in a variety ofdifferent embodiments of which there are many possible permutations.

In an example embodiment, a system is provided with a distributionsection and a manual section. The distribution section may be adjacent aconveyor, and may have a robot adapted to select and pick containersfrom a pallet on the conveyor. The robot is disposed to distribute thecontainer. The manual section is disposed adjacent the conveyor. Themanual section is adapted for filling of the container.

The present disclosure described a camera; it will be understood that aplurality of cameras can be used. The mirror can be shaped to reflectparts of the area where a pharmaceutical to respective cameras. Forexample, the mirror can include a number of parabolas that match thenumber of cameras.

The present disclosure makes reference to a robot and words of similarimport. A robot can be a machine capable of carrying out a complexseries of actions automatically. These complex series of actions mayinclude picking up, orientating, positioning and/or releasing acontainer or other structure. The robot may be dedicated to a singleseries of movements or may be able to execute multiple series ofmovements. A robot may include a processor that received instructionsand then executes instructions to control its movement. In anotherexample, a robot may resemble a human being and replicate certain humanmovements and functions, e.g., a robot may move location, have anarticulated arm, have grasping structures that replicate like fingersand do not damage containers, and the like.

Thus, methods and systems for spill detection have been described.Although embodiments of the present invention have been described withreference to specific example embodiments, it will be evident thatvarious modifications and changes may be made to these embodimentswithout departing from the broader spirit and scope of the embodimentsof the invention. Accordingly, the specification and drawings are to beregarded in an illustrative rather than a restrictive sense.

The methods described herein do not have to be executed in the orderdescribed, or in any particular order. Moreover, various activitiesdescribed with respect to the methods identified herein can be executedin serial or parallel fashion. Although “End” blocks are shown in theflowcharts, the methods may be performed continuously.

In the foregoing Detailed Description, it can be seen that variousfeatures are grouped together in a single embodiment for the purpose ofstreamlining the disclosure. This method of disclosure is not to beinterpreted as reflecting an intention that the claimed embodimentsrequire more features than are expressly recited in each claim. Rather,as the following claims reflect, inventive subject matter may lie inless than all features of a single disclosed embodiment. Thus, thefollowing claims are hereby incorporated into the Detailed Description,with each claim standing on its own as a separate embodiment.

The invention claimed is:
 1. A pharmaceutical filling system comprising:a pharmaceutical dispensing device to respectively dispense differenttypes of pharmaceuticals in a plurality of containers in a filling area;a control device coupled to the pharmaceutical dispensing device; amirror portion coupled to the pharmaceutical dispensing device andincluding a concave mirror; and a camera portion coupled to thepharmaceutical dispensing device and positioned opposite the mirrorportion across a field of view, the camera portion including: a cameraconnected to the control device and oriented towards the mirror portionto capture images, the camera being focused on a reflection in theconcave mirror of the field of view, and a light panel electricallyconnected to the control device and oriented toward the mirror portionto illuminate the field of view; wherein the control device is operableto receive a series of at least three consecutive images captured by thecamera, and determine whether a pharmaceutical spill has occurred byidentifying a falling object present within the field of view in atleast a portion of the series of at least three consecutive images. 2.The pharmaceutical filling system of claim 1, wherein the plurality ofcontainers are retained within a single pallet.
 3. The pharmaceuticalfilling system of claim 1, wherein determination of whether apharmaceutical spill has occurred includes locating any artifacts in theseries of at least three consecutive images above, below, or within apredetermined number of pixels.
 4. The pharmaceutical filling system ofclaim 1, wherein the pharmaceutical dispensing device comprises: afilling cabinet; a prefill assembly housed below the filing cabinet tostore measured quantities of pharmaceuticals received from the fillingcabinet and dispense the measured quantities of pharmaceuticals from thefilling cabinet into a plurality of containers on a pallet; a palletconveyor to transport the pallet including the plurality of containers;and a pallet assembly to receive the pallet from the pallet conveyor andretain the pallet while at least one of the measured quantities ofpharmaceuticals is being dispensed by the prefill assembly into acontainer of the plurality of containers.
 5. The pharmaceutical fillingsystem of claim 1, wherein the pharmaceutical dispensing devicecomprises: a filling cabinet including a plurality of bins; a prefillassembly housed below the filing cabinet to store measured quantities ofpharmaceuticals received from the filling cabinet and dispense themeasured quantities of pharmaceuticals from the filling cabinet into aplurality of containers on a pallet; a pallet conveyor to transport thepallet including the plurality of containers; and a pallet assembly toreceive the pallet from the pallet conveyor and retain the pallet whilea first measured quantity of a first type of pharmaceuticals of themeasured quantities of pharmaceuticals received by the prefill assemblyfrom a first bin of the plurality of bins is being dispensed into afirst container of the plurality of containers and a second measuredquantity of a second, different type of pharmaceuticals of the measuredquantities of pharmaceuticals received by the prefill assembly from asecond, different bin of the plurality of bins is being dispensed into asecond container of the plurality of containers.
 6. The pharmaceuticalfilling system of claim 1, wherein the pharmaceutical dispensing devicetransmits a signal to the control device based on the plurality ofcontainers entering the filling area, wherein the control unit receivesthe series of at least three consecutive images based on receipt of thesignal from the pharmaceutical dispensing device.
 7. A dispensing devicecomprising: a filling cabinet including a plurality of bins; a prefillassembly housed below the filling cabinet to store measured quantitiesof pharmaceuticals received from the filling cabinet and dispense themeasured quantities of pharmaceuticals from the filling cabinet into aplurality of containers on a pallet; a pallet conveyor to transport thepallet including the plurality of containers; a pallet assembly toreceive the pallet from the pallet conveyor and retain the pallet whileat least one of the measured quantities of pharmaceuticals is beingdispensed by the prefill assembly into a container of the plurality ofcontainers; and an optical subsystem to image a spilled pharmaceutical,the optical subsystem including a mirror portion and a camera portion,the mirror portion including a concave mirror, the camera portionincluding a camera and a light panel, the camera being pointed towardsthe center of the concave mirror, the light panel emitting light towardthe concave mirror, wherein the optical subsystem is positioned beneatha fill area of the prefill assembly.
 8. The dispensing device of claim7, wherein the filing cabinet is located on a first, upper floor and theprefill assembly and the pallet assembly are located on a second, lowerfloor below the filling cabinet.
 9. The dispensing device of claim 7,wherein the optical subsystem is positioned adjacent to the palletconveyor within the pallet assembly.
 10. The dispensing device of claim7, wherein the prefill assembly includes a plurality of buffer tubes, abuffer tube of the plurality of buffer tubes being coupled to a bin ofplurality of bins, the buffer tube to retain and dispense the at leastone of the measured quantities of pharmaceuticals into the container.11. The dispensing device of claim 7, wherein the concave mirror isapproximately parabolic.
 12. The dispensing device of claim 7, whereinthe light panel includes a light source and a light diffuser, the lightsource being positioned behind the light diffuser.
 13. The dispensingdevice of claim 7, wherein the optical subsystem begins image capturebased on receipt of the pallet by the pallet assembly.
 14. Thedispensing device of claim 7, wherein the optical subsystem includes acontrol unit to perform blob detection on a plurality of images capturedby the camera.